Tissue-engineered silk organs

ABSTRACT

This invention relates to a lamellae tissue layer, comprising a grooved silk fibroin substrate comprising tissue-specific cells. The silk fibroin substrates provides an excellent means of controlling and culturing cell and extracellular matrix development. A multitude of lamellae tissue layers can be used to create a tissue-engineered organ, such as a tissue-engineered cornea. The tissue-engineered organ is non-immunogenic and biocompatible.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Division of U.S. patent application Ser. No. 14/793,464, filed Jul. 7, 2015, which is a Division of U.S. patent application Ser. No. 12/528,634, filed Mar. 29, 2010, and issued as U.S. Pat. No. 9,102,916 which is a 35 U.S.C. § 371 National Stage of International Application No. PCT/US2008/055072 filed on Feb. 27, 2008, which designates the United States, and which claims benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/973,023, filed Sep. 17, 2007, and U.S. Provisional Application No. 60/903,800, filed Feb. 27, 2007, each of which are herein incorporated by reference in their entirety.

GOVERNMENT SUPPORT

This invention was made with government support under grant EB002520 awarded by the National Institutes of Health. The government has certain rights in the invention.

FIELD OF THE INVENTION

This invention relates to a tissue-engineered silk organs, such as tissue-engineered silk corneas, and processes used to make the tissue-engineered silk organs.

BACKGROUND

Corneal damage causes significant vision loss in the general world population, second only to cataracts, each year. Corneal replacement is a developing technology that is rapidly becoming a necessity for many patients. Many of the reasons for corneal replacement therapies include scarring from disease (e.g. herpes infection), complications from LASIK surgery, hereditary problems (e.g., Fuch's disease), and complications from other surgeries (e.g., cataracts).

Current strategies employed for corneal grafting make use of allogenic or synthetic materials. These strategies are only partially effective, however, and may stimulate host immune responses that result in tissue rejection. In addition, there is the potential for transfer of diseases from unhealthy donor organs. These issues are compounded by the growing use of corrective eye surgery which renders corneas unsuitable for grafting which will further impact the availability of acceptable allogenic supplies.

The use of grooved substrates has been demonstrated in the literature to induce cell and extracellular matrix (ECM) alignment upon various substrates (Ingber, 2003; Dalby et al., 2003; Walboomers et al., 1999; den Braber et al., 1998; Dunn and Brown, 1986). These methods have been employed in part as an effort to control tissue development. Most of the material substrates (i.e. titanium, silicone, PDMS and PEO) used in these studies are not readily degraded by the body or are not suitable for use in vivo. Hence, while possible applications in tissue development have been explored with these substrates, the cultured cells grown upon the substrates cannot be implanted, significantly limiting their practical use. Furthermore, these materials may cause stress induced cell responses that may disrupt normal cell function and tissue development over time.

Thus, what is needed in the art is a tissue-engineered cornea replacement system, made with a material that is optically clear, non-immunogenic, and biocompatible material. This invention answers that need.

SUMMARY OF THE INVENTION

This invention relates to a lamellae tissue layer, comprising a grooved silk fibroin substrate comprising tissue-specific cells. A multitude of lamellae tissue layers can be used to create a tissue-engineered organ having the lamellae tissue layers.

The invention also relates to a process for preparing a tissue-engineered organ. The process involves preparing a multitude of lamellae tissue layers. Each lamellae tissue layer comprises a grooved silk fibroin substrate seeded with tissue-specific cells capable of extracellular matrix deposition. The process then involves culturing the cells on the silk fibroin substrate for a sufficient period of time to allow for the cells and deposited extracellular matrix to form a tissue-engineered organ.

The invention also relates to a tissue-engineered cornea. The tissue-engineered cornea contains at least two lamellae tissue layers, an endothelial cell sheet on the bottom of the lamellae tissue layers, and an epithelial cell sheet on the top of the lamellae tissue layers. Each of the lamellae tissue layers comprise a grooved silk fibroin substrate seeded with fibroblast cells having an extracellular matrix deposition.

The invention also relates to an in vivo implantation system for tissue-engineered organs. The system involves forming a tissue-engineered organ comprising cultured tissue-specific cells on a grooved silk fibroin substrate; allowing the silk fibroin material in the tissue-engineered organ to at least partially degrade; and implanting the tissue-engineered organ into a native tissue.

The invention also relates to a kit for preparing a tissue-engineered organ. The kit includes a grooved silk fibroin substrate capable of receiving tissue-specific cells having an extracellular matrix deposition. The kit also includes instructions for seeding the tissue-specific cells on the silk fibroin substrate, organizing the silk fibroin substrates to form lamellae tissue layers, culturing the tissue-specific cells on the silk fibroin substrate, or a combination thereof.

The invention also relates to an in vitro testing system for animal organ replacement. The system involves forming a cultured tissue system comprising cultured tissue-specific cells on a grooved silk fibroin substrate; incubating the cultured tissue system for a time period until the tissue construct of the tissue-specific cells is able to maintain native tissue characteristics and form cultured tissue; and testing the cultured tissue under in vitro research conditions to aid in the development of animal organ replacement.

The wide range of potential use, mechanical robustness, incorporated vasculature, and all-natural material composition of the silk tissue construct offers a significant advancement in tissue engineering technology. Using silk as a substrate brings together both the ability to better control cell and ECM development, while also offering the advantage of substrate material removal over time.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1(a)-1(b) depicts silk films with cast microgrooves. FIG. 1(a) is a field-emission scanning electron microscope (FESEM) image of groove topology. FIG. 1(b) is an atomic force microscope (AFM) of film surface. In these figures, each groove is approximately 1.7 μm in width and 1 μm in depth.

FIGS. 2(a)-2(d) depicts aligned corneal fibroblasts cells cultured upon grooved silk lamellae substrates. FIGS. 2(a) and 2(c) show the transmission 2(a) and false color confocal images 2(c) of green fluorescent protein (GFP) labeled corneal fibroblasts growing on non-patterned silk films. FIGS. 2(b) and 2(d) show the transmission 2(b) and false color confocal images 2(d) of GFP labeled corneal fibroblasts growing on a groove-patterned silk lamellae surface. Scale bar is 100 um.

FIGS. 3(a)-3(c) depicts scanning electron microscope (SEM) images of aligned fibroblasts corneal cells and ECM on grooved silk lamellae constructs. FIGS. 3(a) and 3(c) show fibroblasts and ECM aligning on grooved silk lamellae. FIG. 3(b) depicts a magnified image of an aligned cell process and clear image of patterned groove geometry upon the silk lamellae.

FIGS. 4(a)-4(c) depicts corneal fibroblasts aligned on silk films and cast with circular geometrical patterns. FIG. 4(a) shows a fluorescent image of GFP labeled corneal fibroblasts grown on circular patterned silk films, and FIG. 4(b) shows a digitally enhanced higher magnification image of the same. FIG. 4(c) shows a circular-patterned cast that can be used for silk films.

FIGS. 5(a)-(b) depicts SEM images of laser ablated micropores in silk lamellae construct. FIG. 5(a) is a line of micropores about 5 microns in diameter. Scale bar is 50 um. FIG. 5(b) is a high-magnification image of a select micropore, which is also about 5 μm in diameter.

FIGS. 6(a)-(c) shows graphs of Alamar Blue metabolic assays for rabbit corneal fibroblast cultures grown on different substrates for 10 days. FIG. 6(a) shows a graph of the cultures at day 1; FIG. 6(b) shows the cultures at day 4; and FIG. 6(c) shows the cultures at day 10.

FIGS. 7(a)-(d) depicts phase contrast images of corneal fibroblasts after 14 days in culture on 7(a) silk coated glass and 7(b) tri-calcium phosphate (TCP) coated glass. The images are magnified by 320 x. Immunofluorescent images for corneal fibroblasts after four days in culture on 7(c) silk-coated glass and 7(d) glass. The lighter areas, shown as green fluorescence in the color images, demonstrate collagen V protein expression.

FIG. 8 is a graph showing the percentage of light that is transmitted through a 30-micron silk fibroin film.

FIG. 9 depicts a schematic of a preferred method of constructing a silk-engineered cornea.

FIGS. 10(a)-(b) depicts images of aligned corneal fibroblasts. FIG. 10(a) shows the corneal fibroblasts within the central region of the silk cornea construct. Multiple layers of cells can be seen below focus plane of cells. FIG. 10(b) shows the corneal fibroblasts growing on grooved-silk lamellae constructs.

FIGS. 11(a)-(b) depicts SEM images of silk films 11(a) produced with poly(ethylene) oxide (PEO) phase separation and exhibiting porosity 11(b) silk films produced without PEO phase separation.

DETAILED DESCRIPTION

This invention relates to a lamellae tissue layer, comprising a grooved silk fibroin substrate comprising tissue-specific cells. A multitude of lamellae tissue layers can be used to create a tissue-engineered organ having the lamellae tissue layers.

Silk fibroin provides a versatile material for constructing lamellae tissue layers. The stability (good strength and toughness), biocompatibility (less immunogenic and pro-inflammatory than collagens or polyesters), slow degradability, purity (no known bioburdens), and modifiability (easily modified to achieve specific cell-binding or cell-activation characteristics) make silk fibroin an ideal candidate for preparing lamellae tissue layers and tissue-engineered organs. Tissue-engineered corneas are particularly desirable because of the transparency of the silk fibroin, including its ability to transmit nearly 100% of visible light.

The tissue-specific cells may be any biological cells of the desired tissue. For instance, if the desired tissue is a cornea, then the tissue-specific cells should be biological cells having corneal properties or being capable of being used with other biological cells having corneal properties. Suitable tissue-specific cells include, but are not limited to, stem cells, fibroblasts, endothelial, epithelial, adipose cells capable of generating tissue-specific extracellular matrix, and combinations thereof.

The grooved silk fibroin substrate is a fabricated silk film designed to induce cell and extracellular matrix alignment. Preferably, the thickness of grooved silk fibroin substrate ranges from about 10 nm to about 1 mm, the groove size is at least 125 nm, and the groove thickness depth is at least 100 nm. More preferably, the thickness of grooved silk fibroin substrate ranges from about 100 nm to about 100 μm, the groove size ranges from about 500 nm to about 10 μm, and the groove thickness depth ranges from about 250 nm to about 5 μm. Most preferably, the thickness of grooved silk fibroin substrate ranges from about 500 nm to about 10 μm, the groove size ranges from about 1 μm to about 5 μm, and the groove thickness depth ranges from about 500 nm to about 3 μm. The silk diffraction gratings may be characterized for surface morphology by known techniques, such as field emission scanning electron and atomic force microscopy. See FIGS. 1(a)-1(b).

Any type of silk fibroin may be used to make the silk fibroin substrate. Silk fibroin produced by silkworms is the most common and is generally preferred. However, there are many different silks, including spider silk, transgenic silks, genetically engineered silks, and variants thereof, that may alternatively be used. As used herein, the term “fibroin” includes silkworm fibroin and insect or spider silk protein (Lucas et al., Adv. Protein Chem 13: 107-242 (1958)). Preferably, fibroin is obtained from a solution containing a dissolved silkworm silk or spider silk. The silkworm silk protein may be obtained, for example, from Bombyx mori, and the spider silk is obtained from Nephila clavzes. In the alternative, the silk proteins can be obtained from a solution containing a genetically engineered silk, such as from bacteria, yeast, mammalian cells, transgenic animals or transgenic plants. See, for example, PCT Publication WO 97/08315 and U.S. Pat. No. 5,245,012, both of which are herein incorporated by reference in their entirety.

An aqueous silk fibroin solution may be prepared from the silk fibroin using techniques known in the art. Suitable processes for preparing silk fibroin solution are disclosed in PCT Application No. PCT/US2004/011199, and U.S. Provisional Application No. 60/856,297, filed Nov. 3, 2006, entitled “Biopolymer Photonic Crystals and Method of Manufacturing the Same,” both of which are herein incorporated by reference in their entirety.

For instance, the silk fibroin solution may be obtained by extracting sericin from the cocoons of a silkworm silk, such as Bombyx mori. For example, B. mori cocoons can be boiled for about 30 minutes in an aqueous solution, preferably an aqueous solution having about 0.02M Na₂CO₃. The cocoons can then be rinsed with water, for example, to extract the sericin proteins. The extracted silk can then be dissolved in an aqueous solution, preferably an aqueous salt solution. Salts useful for this purpose include lithium bromide, lithium thiocyanate, calcium nitrate or other chemicals capable of solubilizing silk. Preferably, the extracted silk is dissolved in about 9-12 M LiBr solution. The salt may later be removed using, for example, dialysis.

Alternatively, the silk fibroin solution may be obtained from a solution containing a dissolved spider silk, such as Nephila ciavipes. The silk fibroin solution can also be obtained from a solution containing a genetically engineered silk. The genetically engineered silk can, for example, comprise a therapeutic agent, e.g., a fusion protein with a cytokine, an enzyme, or any number of hormones or peptide-based drugs, antimicrobials and related substrates.

Biocompatible polymers can also be added to the silk solution to generate composite matrices. Biocompatible polymers useful in the compositions described herein include, for example, polyethylene oxide (PEO) (U.S. Pat. No. 6,302,848), polyethylene glycol (PEG) (U.S. Pat. No. 6,395,734), collagen (U.S. Pat. No. 6,127,143), fibronectin (U.S. Pat. No. 5,263,992), keratin (U.S. Pat. No. 6,379,690), polyaspartic acid (U.S. Pat. No. 5,015,476), polylysine (U.S. Pat. No. 4,806,355), alginate (U.S. Pat. No. 6,372,244), chitosan (U.S. Pat. No. 6,310,188), chitin (U.S. Pat. No. 5,093,489), hyaluronic acid (U.S. Pat. No. 387,413), pectin (U.S. Pat. No. 6,325,810), polycaprolactone (U.S. Pat. No. 6,337,198), polylactic acid (U.S. Pat. No. 6,267,776), polyglycolic acid (U.S. Pat. No. 5,576,881), polyhydroxyalkanoates (U.S. Pat. No. 6,245,537), dextrans (U.S. Pat. No. 5,902,800), and polyanhydrides (U.S. Pat. No. 5,270,419). Two or more biocompatible polymers can be used in combination.

The silk fibroin substrate may be prepared by casting a silk solution onto patterned diffractive optical surfaces, such as different holographic diffraction gratings with varying line pitches as masks. After the silk solution has been cast, they can be dried as films. Drying may be accomplished by any means known in the art. For instance, the films may be placed in a vacuum environment and water annealed for two or more hours, removed, and allowed to further dry. Removal from the grating mask can be accomplished by simple mechanical lifting of the grating from the substrate.

The grooves of the silk fibroin substrate induce cell and ECM alignment. Thus, the tissue-specific cells have deposited extracellular matrix on the substrate. See FIGS. 2(a)-2(d). The cultured cells grown on the silk films align and form their ECM parallel to the grooved film pattern. See FIGS. 2(a)-2(d) and 3(a)-(c). This allows one to control the direction of cell orientation and tissue alignment upon the lamellae layer, something that is helpful in tissue formation. Geometrical shapes imprinted on the substrates may also be used to grow the cells in aligned patterns. See FIGS. 4(a)-4(c). Varying the geometrical pattern upon the silk film allows for defined spatial patterning of cell growth for the targeted tissue system.

The individual lamellae tissue layers, each of which is virtually a two-dimensional (2-D) construct containing the silk film and tissue-specific cell types, can then be stacked upon one another or otherwise combined to produce a three-dimensional (3-D) tissue-engineered organ. These 2-D lamellae structures can thus serve as “building-blocks” for 3-D tissue engineered constructs. Such a system exploits the advantageous material features of silk fibroin, including its slow degradation, biocompatibility, optical transparency, and durability for handling and suturing.

The edges of the multi-layer construct may be sealed to prevent diffusion. Because the silk substrates are self adhering when exposed to applied pressure, a dulled biopsy punch which corresponds to the round silk film geometry can be used to apply pressure upon seeding. Alternatively, polydimethylsulfoxide (PDMS) discs of similar diameter to the silk substrate may be employed to act as a clamping mechanism to hold the layers in place. PDMS has been shown to be inert in cell culture, has low water sorption, and can induce a passive clamping force. If the self-adherence mechanism is not sufficient, fibrin glue or similar adhesive can also be used.

In view of the inherent control and ability of the protein found in the silk fibroin, the functional material requirements of the desired tissue system can be closely matched and then interfaced with the tissue specific cell type. The lamellae “building-block” tissue system is applicable to multiple organ systems, provides a range of tunable material properties, and is completely, or at least mostly, composed of biomaterials that are non-immunogenic upon implantation. The resulting tissue-engineered organ thus contains silk fibroin substrates with cultured cells and deposited extracellular matrix.

Because of diffusion limitations, cells located in the central regions of tissue-engineered organs many times do not receive sufficient levels of nutrients required to support cellular life. To better support cell viability, the tissue-engineered organs may contain a vasculature network able to supply nutrient diffusion throughout the entire tissue-engineered construct. Incorporating micropores into the tissue-engineered organ mimics the convection for efficient nutrient transport and allows for nutrient diffusion or vascularization to each lamellae tissue layer of the biological construct.

The vasculature-like micropores may be “drilled” in defined patterns within the silk film using polymer phase separation chemistry, laser ablation techniques, or other techniques known in the art. Laser ablation technology, such as Femtosecond laser ablation technology, involves high energy pulsed laser light to minimize peripheral damage to the material. Polymer phase separation chemistry involves mixing two polymers that do not mix well (immiscible, akin to oil and water) to exploit their inability to mix well, such that they separate into different domains to generate materials morphologies based on the polymers and their respective amounts. Preferred polymers for use in polymer phase separation include polyethylene oxide or similar alternative polymers and waxes.

Porosity within the silk films can often times be systematically controlled. When using laser ablation technology, porosity can be altered based on the size or the focus of the laser. When using polymer phase separation chemistry, porosity size range and pore density can be controlled by varying the concentration of the polymer. By holding constant the other variables, such as casting volume, casting surface area, and silk concentration (or multiple variables changed at the same time), porosity can be dependent, do a large degree, on polymer concentration. See Example 4.

The micropores should be small enough so that the material properties of the lamellae tissue layers are not compromised and can still maintain a robust matrix for tissue development, yet large enough to provide the desired vascularization. Preferably, the average diameter of the micropores ranges from about 100 nm to about 100 micron. More preferably, the average diameter ranges from about 800 nm to about 20 micron. Most preferably, the average diameter ranges from about 1 micron to about 10 micron. See FIGS. 5(a)-5(b).

The micropores are preferably incorporated into the tissue-engineered organ in patterns designed to optimize nutrient diffusion to culture surface area specific to the targeted tissue system. As the layers are stacked upon one another, the microporous structure allows for nutrient diffusion to all regions of the 3-D construct.

Various designs or patterns can be used when creating the micropores. For tissue-engineered corneas, a 50-100 μm spacing is preferred because it provides an averaged spaced vascular network similar to that found in corneal tissue (although corneal tissue is not vascularized by blood capillaries, it contains a network that assists in nutrient diffusion through the tissue). Generating arrays of micron- or nano-sized holes interspersed in grid spacing provides nutrient diffusive ports throughout the stacked silk lamellae tissue layers.

The lamellae tissue layers may be used to produce various tissue types and organ systems. Such systems may include bone, skin, cardiac tissue, cardiac muscle, muscle tissue, dense connecting tissue, basement membranes, smooth muscle tissue, endothelial tissue, and nervous tissue. The organ can be made up of any tissue that can be formed by the assembly of the silk fibroin substrates with cultured cells and deposited extra cellular matrix. Preferably, the organ is a cornea, which is particularly suited for silk-based lamellae tissue layers because of the optically clear, non-immunogenic properties, and biocompatibility of the silk fibroin.

The invention also relates to a process for preparing a tissue-engineered organ. The process involves preparing a multitude of lamellae tissue layers. Each lamellae tissue layer comprises a grooved silk fibroin substrate seeded with tissue-specific cells capable of extracellular matrix deposition. The process then involves culturing the cells on the silk fibroin substrate for a sufficient period of time to allow for the cells and deposited extracellular matrix to form a tissue-engineered organ. Optionally, the process also involves creating micropores in the silk film. Through the use of silk fibroin, the tissue-engineered organ can be both non-immunogenic and biocompatible.

Seeding the silk fibroin substrate may be accomplished through means known in the art. Generally, the cells should be seeded in the substrate in a manner that best enables their ability to be cultured within the substrate construct. For example, the cells should typically be distributed at a density of about 1000 cells/cm² to about 50,000 cells/cm². Preferably, the cells should be distributed at a density of about 5000 cells/cm² to about 20,000 cells/cm². Of course, these distribution patterns may differ depending on the size of the cell, the seeding conditions, and other factors appreciated by those of skill in the art.

When seeding the cells in the silk substrate, the cells may be supplemented with other materials known in the art to promote cell growth. Materials known to promote cell growth include cell growth media, such as Dulbecco's Modified Eagle Medium (DMEM), fetal bovine serum (FBS), non-essential amino acids and antibiotics, and growth and morphogen factors such as basic fibroblast growth factor (bFGF), transforming growth factors (TGFs), Vascular endothelial growth factor (VEGF), insulin-like growth factor (IGF-I), bone morphogenetic growth factors (BMPs), nerve growth factors and related proteins.

Additional materials that can be included when seeding the cell include DNA, siRNA, antisense, plasmids, liposomes and related systems for delivery of genetic materials; peptides and proteins to active cellular signaling cascades; peptides and proteins to promote mineralization or related events from cells; adhesion peptides and proteins to improve gel-tissue interfaces; antimicrobial and antifungal peptides and proteins and related compounds. The additional materials can also include common components found in pharmaceutical formulations, such as known excipients. Exemplary excipients include diluents, solvents, buffers, solubilizers, suspending agents, viscosity controlling agents, binders, lubricants, surfactants, preservatives and stabilizers.

The silk fibroin substrate of the lamellae tissue layers provides a mechanically robust matrix to support cellular growth until the culture has reproduced at least part of its original matrix. The amount of time involved in culturing the cells is dependent on the type of cells used, the conditions of the culturing, the degree to which the culture should represent the original matrix, and other variables appreciated by those of skill in the art. Typically, after the silk fibroin substrate has been seeded, the cells are cultured for approximately 1-6 weeks, whereupon the silk fibroin protein will have been at least partially degraded and the new tissue construct exhibits properties consistent with those of the original matrix. It is at this point that the tissue-engineered organ is typically ready for in vivo use or as a tissue system for ex vivo studies.

The cells may be cultured in accordance with techniques known in the art. For instance, the cells may be cultured in an organotypic environment, such as in submerged culture, at air-liquid interfaces or in selective perfusion bioreactors, or other environments suitable for culture cells on silk fibroin substrates.

When preparing a tissue-engineered cornea, an endothelial cell sheet may be added on the bottom of the lamellae tissue layers and an epithelial cell sheet may be added on the top of the lamellae tissue layers. In this preferred embodiment, the invention relates to a tissue-engineered cornea containing at least two lamellae tissue layers, an endothelial cell sheet on the bottom of the lamellae tissue layers, and an epithelial cell sheet on the top of the lamellae tissue layers. Each of the lamellae tissue layers comprise a grooved silk fibroin substrate seeded with fibroblast cells having an extracellular matrix deposition. Preferably, the cornea is optically clear, non-immunogenic, and biocompatible, and the lamellae tissue layers comprise micropores that allow for nutrient diffusion to each layer.

The invention also relates to an in vivo implantation system for tissue-engineered organs. The system involves forming a tissue-engineered organ comprising cultured tissue-specific cells on a grooved silk fibroin substrate; allowing the silk fibroin material in the tissue-engineered organ to at least partially degrade; and implanting the tissue-engineered organ into a native tissue. The in vivo implantation system may be applicable to multiple organ systems, provides a range of tunable material properties, and is completely, or at least mostly, composed of biomaterials that are non-immunogenic upon implantation.

The determination of when a tissue-engineered organ is ready for implantation should generally be left to the expertise of the skilled artisan. Typically, implantation into a native tissue may be done when the silk fibroin material has at least partially degraded and the culture has reproduced to a point at or near its original matrix.

The invention also relates to a kit for preparing a tissue-engineered organ. The kit includes a grooved silk fibroin substrate capable of receiving tissue-specific cells having an extracellular matrix deposition. The kit also includes instructions for seeding the tissue-specific cells on the silk fibroin substrate, organizing the silk fibroin substrates to form lamellae tissue layers, culturing the tissue-specific cells on the silk fibroin substrate, or a combination thereof. The instructions need only be provided in detail sufficient to enable a skilled artisan to use the kit consistent with its primary use of preparing a tissue-engineered organ.

The kit may additionally include other tools known in the art to be helpful in preparing a tissue-engineered organ. For example, the kit may contain a collecting and containment tool set for acquiring cells from a primary cell source, such as a human or an animal. The kit may also contain a bioreactor for culturing the silk fibroin substrate after the substrate has been seeded with the tissue-specific cells. The bioreactor is preferably capable of maintaining sterile and nutrient-filled conditions until the tissue-specific cells have been cultured.

Various uses of the kit are contemplated. The kit may be used in the academia and industry for commercial testing or other types of commercial use. In a preferred embodiment, the kit may be used to prepare a tissue-engineered organ for commercial testing purposes.

The invention also relates to an in vitro testing system for animal organ replacement. The system involves forming a cultured tissue system comprising cultured tissue-specific cells on a grooved silk fibroin substrate; incubating the cultured tissue system for a time period until the tissue construct of the tissue-specific cells is able to maintain native tissue characteristics and form cultured tissue; and testing the cultured tissue under in vitro research conditions to aid in the development of animal organ replacement.

The time period for incubating the cultured tissue system varies depending on the tissue system, the incubation conditions, the amount of organ that is being replaced, and other variables appreciated by those of skill in the art. If only a small portion of an organ is being replaced under favorable incubation conditions, the time period will obviously be shorter than if a large portion or a complete organ is being replaced under strained conditions. The exact time period can be determined by one of skill in the art under the circumstances of the organ replacement. Typically, the cultured tissue system is incubated for approximately 1-6 weeks.

Testing the cultured tissue involves any aspects of testing that one of skill in the art would typically conduct in a research setting. The results, or lack of results, obtained through this testing should be viewed as aiding in the development of animal organ replacement.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods and materials are described below. All publications, patent applications, patents and other references mentioned herein are incorporated by reference. In addition, the materials, methods and examples are illustrative only and not intended to be limiting. In case of conflict, the present specification, including definitions, controls.

The invention will be further characterized by the following examples which are intended to be exemplary of the invention.

EXAMPLES Example 1: Silk as a Substrate for Corneal Cell Growth

Silk has been shown to be a viable substrate for a number of different cell types. Silk tissue layers are also capable of supporting corneal cell growth comparative to tissue culture plastic using the Alamar Blue metabolic cell assay. See FIGS. 6(a)-6(c). As shown in FIGS. 6(a)-6(c), similar cellular metabolic rates were found upon silk, glass and TCP substrates. These data show the ability to produce lamellae tissue layers as building-blocks for tissue-engineering purposes. It also provides support for the production of silk tissue-engineered cornea.

Example 2: Rabbit Stromal Fibroblasts

The ability of rabbit stromal fibroblasts to grow on silk fibroin substrates was assessed. A monolayer of 8% fibroin solution was deposited on 12 mm round glass coverslips using a spin coater (Laurell Technologies). The spin coater produces an even distribution of the fibroin polymer across the glass surface. The fibroin coated coverslips were steam sterilized and placed within 24-well culture dishes. Primary corneal fibroblasts were isolated from adult rabbit corneas and cultured to confluency on TCP. The cells were then seeded at a density of 10,000 cells/cm² on the fibroin coated coverslips, and supplemented with media containing Dulbecco's Modified Eagle Medium (DMEM), 10% fetal bovine serum (FBS), and 1% Penstrep (an antibiotic treatment to reduce contamination of the cell cultures). The cells where grown to confluency and the morphology of the cells appeared similar to fibroblasts grown on TCP. See FIGS. 7(a)-7(d).

To ensure that the cultured cells were stromal fibroblasts, immunostaining was used to localize collagen V, a protein produced in abundance by corneal stromal fibroblasts. Collagen V is produced by corneal keratocytes in situ within the stromal matrix and acts to regulate collagen fibril diameter. See Marchant et al., 1996; and Birk et al., 1990, both of which are herein incorporated by reference in their entirety. The immunostaining provides evidence that this protein was generated by the corneal fibroblasts seeded on the silk fibroin substrates. These preliminary results suggest that rabbit corneal fibroblasts retain their differentiated phenotype on silk fibroin substrates.

Example 3: Tissue-Engineered Silk Cornea

Silk fibroin substrates may be transformed into lamellae tissue layers capable of guiding cell and ECM development and can also be vascularized or porous networks generated to support nutrient diffusion. These lamellae tissue layers can then be combined to form a 3-D tissue construct, or a tissue-engineered organ.

The corneal tissue system offers a unique set of parameters that make it a useful model system for the use of the lamellae structures, in that the tissue is largely composed of stacked layers of extracellular matrix interspersed with cell layers. The lamellae tissue layers provide the correct set of material characteristics needed to form corneal tissue in that silk fibroin is robust in its mechanical properties, degrades naturally with native tissue replacement by the seeded cells, is non-immunogenic, and is optically clear with near 100% transmission of visible light. See FIG. 8.

The tissue layers may be used to produce tissue-engineered organs, such as corneal stromal tissue analogs. A schematic of a process that can be used to form an entire corneal tissue is shown FIG. 9. Other configurations can also be used. In FIG. 9, stacked lamellae tissue layers are placed between endothelial and epithelial cell sheets on the bottom and top of the stacked stroma region respectively. See Nishida et al., 2003, herein incoporated by reference in its entirety, for a description of the endothelial and epithelian cell sheets.

The entire tissue-engineered organ can then be cultured in an organotypic environment until it is ready for implantation or ex vivo tissue experimentation. Studies show that cell growth was detected within the central regions of the tissue-engineered silk cornea construct, suggesting cell viability is present throughout the construct. See FIGS. 10(a)-10(b).

Example 4: Controlling Silk Film Porosity by PEO Phase Separation

Materials: 8% silk solution, 5% poly(ethylene oxide) (PEO) solution, water and methanol were used. A desiccator, polydimethysulfoxide (PDMS) substrates, Teflon cover slips, a Teflon drying surface, tube racks, tweezers, 1-mL syringes, micro-centrifuge tubes, and 24-well plates.

Methods: A silk fibroin aqueous solution is prepared using standard protocols known in the art. The silk/PEO films are cast on PDMS, such as patterned or flat surfaces. A 5% wt. vol. PEO solution was prepared. 100-uL of silk/PEO solution dilution was cast onto 2-cm² patterned and flat round PDMS surfaces. The film was allowed to dry for 12-hrs. Upon drying, the films were water annealed for 6-hrs to induce primary beta-sheet crystallinity. After water annealing, the films were submerge in a water bath to prevent excessive film dehydration. The water bath was covered and the films allowed to sit for 24-hrs. One film was transferred from the water bath into a 100% MeOH bath for secondary beta-sheet crystallinity induction. The film was allowed to sit for 2-minutes, and then peeled off of their respective PDMS surfaces while submerged in the methanol bath. Once removed, the films were floated onto a Teflon coated glass slide, removed from the MeOH bath, and placed onto a Teflon coated drying surface (i.e. acrylic coated surfaces).

Results: Micro-pores were created within silk films by using PEO phase separation chemistry techniques to promote increased nutrient diffusion and cell-to-cell interaction throughout a stacked film construct. See Jin et al., 2004, herein incorporated by reference in its entirety. The ratio of silk-to-PEO used in casting directly influenced the pores generated in the films once formed, dried and the PEO is extracted. Pores ranging between 1-3 microns in diameter were produced within the film. See FIG. 11(a). In contrast, no pores were exhibited in controls not using the PEO separation method. See FIG. 11(b) as a comparative example.

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We claim:
 1. A grooved substrate comprising silk fibroin, wherein thickness of the substrate ranges from 10 nm to 1 mm, wherein groove width is at least 125 nm, and wherein the substrate comprises micropores, wherein spacing between the micropores is 50 μm to 100 μm and, wherein an average diameter of the micropores ranges from 100 nm to 10 μm.
 2. The grooved substrate of claim 1, wherein groove thickness depth is at least 100 nm.
 3. The grooved substrate of claim 1, wherein the silk is selected from the group consisting of silkworm silk, spider silk, transgenic silk and genetically engineered silk.
 4. The grooved substrate of claim 1, wherein the substrate comprises patterned diffractive optical surfaces.
 5. The grooved substrate of claim 1, wherein the substrate comprises beta-sheet crystallinity, and wherein the beta-sheet crystallinity is induced by water annealing.
 6. The grooved substrate of claim 1, wherein the micropores are created through the use of poly(ethylene oxide) phase separation chemistry, laser ablation techniques, or a combination thereof.
 7. The grooved substrate of claim 1, wherein the substrate is non-immunogenic, and biocompatible.
 8. The grooved substrate of claim 1, further comprising at least one non-patterned silk film or circular patterned silk film. 